US3060072A - Backed carpet and method of producing the same - Google Patents

Backed carpet and method of producing the same Download PDF

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Publication number
US3060072A
US3060072A US85306859A US3060072A US 3060072 A US3060072 A US 3060072A US 85306859 A US85306859 A US 85306859A US 3060072 A US3060072 A US 3060072A
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US
United States
Prior art keywords
layer
pile
base
adhesive
fibrous material
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
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English (en)
Inventor
David B Parlin
William J Elliott
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Bigelow Sanford Inc
Original Assignee
Bigelow Sanford Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to LU38499D priority Critical patent/LU38499A1/xx
Application filed by Bigelow Sanford Inc filed Critical Bigelow Sanford Inc
Priority to US85306859 priority patent/US3060072A/en
Priority to FR823542A priority patent/FR1253594A/fr
Priority to GB1316860A priority patent/GB894234A/en
Priority to CH425360A priority patent/CH372268A/fr
Priority to DEB57517A priority patent/DE1238430B/de
Application granted granted Critical
Publication of US3060072A publication Critical patent/US3060072A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
    • D05C17/02—Tufted products
    • D05C17/023—Tufted products characterised by the base fabric
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23979—Particular backing structure or composition

Definitions

  • the present invention relates to backed carpet and the method of producing the same.
  • ⁇ lt relates, more particularly, to a backing which is especially useful in conjunction with tufted carpet and the -method of forming such backing on a carpet.
  • An object of the present invention is to provide a backed carpet which is dimensionally stable and which has substantial bulk or body.
  • Carpet embodying the present invention is substantially immune to shrinkage and thus, can be washed or shampooed without fear of dimensional changes.
  • Another object of the invention is to provide an economical method of forming such a backed carpet.
  • a further object of the present invention is to provide a method of applying a layer of reinforcing material and the binding of the pile elements to the base of the carpet without materially increasing the cost of the carpet while at the same time producing a carpet of superior quality.
  • tufted carpet lacks bulk or body and dimensional stability because the pile elements are ordinarily formed on a relatively imsy base, such as burlap or lightweight canvas and the present invention corrects these deficiencies to a large extent.
  • an adhesive material such as a latex compound
  • reinforcing materials of various kinds and thicknesses to the back of the carpet in order to obtain the desired dimensional stability. This of course, adds materially to the cost of the carpet and due to the nature of the reinforcing material has not been entirely satisfactory.
  • increased bulk and dimensional stability in the carpet are obtained by attaching a layer of fibrous material to the base of the carpet in such a way that fibers from the layer not only extend into the material forming the base of the carpet but in some instances penetrate the yarns forming the pile elements.
  • An adhesive material in liquid form is then applied to the layer of fibrous material, and the layer of fibrous material with the adhesive thereon is then compacted into a relatively thin layer impregnated with the adhesive material.
  • the adhesive material binds the fibers forming the layer of fibrous material together while at the same time bonding the layer to the base of the carpet and securing the pile elements in place.
  • FIG. l is a side view in vertical section diagrammatically illustrating a tufted carpet on an enlarged scale
  • FIG. 2 is a side view in vertical section diagrammatically illustrating the carpet shown in FIG. l with a layer of fibrous material attached thereto;
  • FIG. 3 is a side view in vertical section diagrammatically illustrating the carpet of FIG. 2 after final treatment in accordance with and embodying the present invention
  • FlG. 4 is a diagram-matic view illustrating the manner attenta Patented Get. 23 1962 ice ⁇ ly illustrating a base for a tufted carpet with a layer of fibrous reinforcing material attached thereto;
  • FIG. 7 is a side view in vertical section diagrammatically illustrating the structure shown in FIG. 6 with tufted carpet loops formed thereon;
  • FIG. 8 is a side view in vertical section diagrammaticalp 1y illustrating the carpet in FIG. 7 after treatment in accordance with the present invention.
  • a tufted pile fabric 1d comprising pile elements 11 in the form of loops which are supported on a base 12 of loosely woven material, such as burlap or a lightweight canvas.
  • the looped pile elements 11 are formed on the base 12 in the usual manner by a tufting machine with the thread or yarn forming the pile elements extending through the base and beyond the upper face thereof.
  • a layer 13 of loosely compacted fibrous material such as jute, nylon, fiber glass or the like, is next attached to the underside of the base of the pile fabric.
  • the layer 13 of fibrous material is attached to the base of the pile fabric by a needling operation which may be carried out on a needling machine, as indicated in FIG. 4.
  • the fabric is fed forward in inverted position (with the pile facing down) beneath a series of ⁇ vertically reciprocating barbed needles 15 with the layer 13 of fibrous material in the form of a web on top of the base of the fabric.
  • the layer of fibrous material is fed onto the pile fabric beneath a guide plate 16 by a rotating feed wheel 17.
  • the needling of the fibrous layer to the pile fabric is done in a random manner and the needles employed should be smaller in diameter than the strands from which the base of the fabric is formed so that such strands will not be severed and the fabric weakened thereby.
  • the vertical movement of the needles with respect to the fabric will carry some of the fibers from the layer of fibrous material through the base of the fabric, as indicated at 13a, but this movement should be limited so that such fibers will not extend substantially beyond the face of the fabric from which the pile elements extend.
  • the needles will, in some instances, strike the yarns forming the pile elements, with the result that small punctures or openings are made therein into which fibers from the layer of fibrous material are forced, as indicated at 13b.
  • the penetration of the pile yarns by the fibers in this manner adds to the bulk or body of these elements in the carpet.
  • the fabric with the layer of fibrous material attached thereto is then treated in accordance with the procedure illustrated in FIG. 5.
  • the fabric with the layer of fibrous material attached thereto is fed from a roll 21 with the pile facing upwardly over a steaming device 22 which directs steam against a layer of fibrous material on the bottom of the fabric to condition it for reception of an adhesive material.
  • the layer of fibrous material is then impregnated with an adhesive material by passing it over a roll 23 4of an adhesive applying device.
  • the -roll 23 with which the layer of fibrous material contacts, is rotatably mounted in a tank 24 and is partially immersed in a supply of suitable adhesive material 25 in liquid form which is capable of penetrating the layer of fibrous material.
  • the adhesive material used may be a Water-based emulsion of a vulcanizable latex compound containing suitable fillers, pigmenting agents, vulcanizing accelerators, dispersants, antioxidants and the like of the type which are commonly used.
  • the adhesive material should be fluid enough so that it will penetrate the layer of fibrous material readily and it should be of a flexible and rubbery character when cured.
  • Wingstay S alkyl aryl phenol
  • the adhesive applying roll 23 preferably rotates in a direction opposite to the movement of the fabric and the layer of brous material.
  • a doctor blade 26 which contacts the bottom of the carpet after application of the adhesive material spreads the coating of adhesive material over the bottom of the carpet uniformly and returns the excess to .the supply tank.
  • Sufficient adhesive material is applied to the back of the carpet to impregnato the layer of fibrous material and to penetrate into the base of the pile fabric and -any small punctures or openings therein.
  • the layer of fibrous material is then subjected to the action of a burnishing roll 27 which rotates in the same direction as the fabric and the layer of brous material is moving, but at a greater speed.
  • the burnishing wheel compacts the impregnated layer of fibrous material to a thin layer 30 of substantially uniform thickness having a relatively smooth bottom surface and it also aids in forcing the adhesive material through the layer of fibrous material into contact with the base of the pile fabric and into small openings or interstices therein.
  • the adhesive material is dried and cured by passing ⁇ fhe fabric with the compacted layer of impregnated fibrous material through a suitable drying and curing oven 28. After leaving the drying and curing oven, the finished carpet may then be wound into a roll 29.
  • Rolls 3S apply tension to the carpet as it passes over the adhesive applying roll and the burnishing roll.
  • the pile elements are securely bound in place in the base by the adhesive material and the compacted layer 30 of fibrous material is firmly attached to the base by the fibers which extend into the base and the bonding action of the adhesive material.
  • the adhesive material bonds the fibers of the compacted layer together and imparts substantial strength to it.
  • the layer of fibrous material resists dimensional changes in the fabric due to stretching, shrinkage or the like.
  • the web or layer of fibrous material may have a thickness of approximately one-eighth of an inch or slightly more.
  • the adhesive material After the adhesive material has been applied and the layer has been subjected to the action -of the burnishing wheel, its thickness will have been reduced to one-sixteenth of an inch or less and the individual fibers will be securely bonded together by the adhesive material. This imparts considerable tensile strength to the layer which will resist any tendency of the fabric to stretch or shrink. After burnishing, the lower surface of the layer is relatively smooth and lint free.
  • the compacted layer of fibrous material not only adds dimensional stability to the carpet and increases its body or bulk, but it also provides a tough flexible covering which protects the base of the fabric and the pile elements formed thereon.
  • the construction of the carpet may be modified by first attaching a layer 31 of fibrous material to a base 32 of burlap or the like, by a needling operation and then forming pile elements 33 thereon by a tufting operation.
  • the pile fabric with the layer of fibrous material attached thereto are then subject to the operations described above in conjunction with FIG. 5 so that the layer of fibrous material is impregnated with an adhesive material and is reduced in thickness to form a compacted layer 34.
  • Pile carpeting having improved dimensional stability which comprises a base element, a plurality of pile elements supported by and extending from one face of said base Yelement and a dirnensionally stable compacted layer of fibrous material extending over and being permanently secured to an opposite face of the base element, said compacted layer being comprised of fibers distributed at random with fibers therefrom extending into engagement with the base element and a flexible adhesive extending throughout said layer and bonding the fibers of the layer against movement relative to each other in a compacted condition ⁇ whereby said layer is rendered dimensionally stable, said adhesive also bonding the layer to the base element of the carpeting and bonding the pile elements to the base element of the carpeting.
  • Pile carpeting having improved dimensional stability which includes a base element comprising a loosely woven material, tufted pile elements formed on said base element, said pile elements having portions extending from one face of the base element and avcompacted layer of fibrous material extending over and being bonded to an opposite face of the base element, said layer being needled to the base element and being comprised of fibers distributed at random with bers therefrom extending into interstices of the woven material forming the base element and a exible adhesive extending throughout said layer and bonding the fibers of the layer against movement relative to each other in a compacted condition, said adhesive also extending into the interstices in the woven material forming the base element and bonding the compacted layer and the pile elements to the base element.
  • Pile carpeting having improved dimensional stability as defined in claim 2 wherein the adhesive penetrates portions of the pile elements through needle punctures therein and lends body thereto.
  • a method of forming pile carpeting having improved dimensional stability which comprises the steps of forming a layer of brous material on a rear face of a piece of pile carpeting having a base and pile elements extending from a front face of the base, applying an adhesive in a flowable state to the layer of brous material, compressing the layer of fibrous material while the adhesive is in a owable state into a compacted condition and simultaneously forcing the adhesive throughout the layer and into the base of the pile carpeting, and then drying the adhesive whereby the bers of the layer are bonded together in a compacted condition and the layer is bonded to the base of the pile carpeting.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing Of Multi-Layer Textile Fabrics (AREA)
  • Carpets (AREA)
  • Laminated Bodies (AREA)
US85306859 1959-11-16 1959-11-16 Backed carpet and method of producing the same Expired - Lifetime US3060072A (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
LU38499D LU38499A1 (de) 1959-11-16
US85306859 US3060072A (en) 1959-11-16 1959-11-16 Backed carpet and method of producing the same
FR823542A FR1253594A (fr) 1959-11-16 1960-04-06 Tapis à envers renforcé et son procédé de fabrication
GB1316860A GB894234A (en) 1959-11-16 1960-04-13 Backed carpet and method of producing same
CH425360A CH372268A (fr) 1959-11-16 1960-04-14 Tapis à envers renforcé et son procédé de fabrication
DEB57517A DE1238430B (de) 1959-11-16 1960-04-19 Hinterfuetterter Noppenteppich

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US85306859 US3060072A (en) 1959-11-16 1959-11-16 Backed carpet and method of producing the same

Publications (1)

Publication Number Publication Date
US3060072A true US3060072A (en) 1962-10-23

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ID=25314946

Family Applications (1)

Application Number Title Priority Date Filing Date
US85306859 Expired - Lifetime US3060072A (en) 1959-11-16 1959-11-16 Backed carpet and method of producing the same

Country Status (6)

Country Link
US (1) US3060072A (de)
CH (1) CH372268A (de)
DE (1) DE1238430B (de)
FR (1) FR1253594A (de)
GB (1) GB894234A (de)
LU (1) LU38499A1 (de)

Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3166465A (en) * 1960-05-27 1965-01-19 Int Latex Corp Bakced pile fabric and method of producing the same
US3206343A (en) * 1958-12-23 1965-09-14 Celanese Corp Method of pile construction
US3332828A (en) * 1965-12-28 1967-07-25 Monsanto Co Monofilament ribbon pile product
US3347731A (en) * 1963-01-10 1967-10-17 Tapijtfabriek Noordester N V Device for manufacturing pile products
US3360421A (en) * 1963-05-10 1967-12-26 Du Pont Bonded nonwoven backing material having perforate selvage and carpet made therefrom
US3394043A (en) * 1963-10-31 1968-07-23 Bigelow Sanford Inc Tufted carpet and non-woven backing fabric therefor
US3414458A (en) * 1965-12-16 1968-12-03 Du Pont Non-cracking tufted carpet with nonwoven secondary backing and method of making same
US3535192A (en) * 1968-04-15 1970-10-20 Hale Mfg Co Carpet and method of making same
US3535178A (en) * 1963-10-31 1970-10-20 Bigelow Sanford Inc Method of producing tufted pile fabric and nonwoven backing fabric for the same
US3546059A (en) * 1964-05-04 1970-12-08 Grace W R & Co Composite fibrous article bonded with novel copolymer compositions and method of making same
US3719546A (en) * 1968-03-14 1973-03-06 Bigelow Sanford Inc Lubricated non-woven fabric
US3871948A (en) * 1971-04-01 1975-03-18 Bigelow Sanford Inc Non-woven carpet material with resilient backing
US4104213A (en) * 1976-11-26 1978-08-01 Cpc International Inc. Starch replacement for latex polymer
US5458944A (en) * 1994-04-15 1995-10-17 Fiberweb North America, Inc. Stretchable tufted carpet and stretchable nonwoven carpet backing therefor
US5630896A (en) * 1992-05-01 1997-05-20 Hoechst Celanese Corporation Method of making recyclable tufted carpets
US20110083792A1 (en) * 2008-06-05 2011-04-14 Entwicklungsgesellschaft Fuer Akustik (Efa) Mit Beschraenkter Haftung Velour carpet with tufting-like surface

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3449784A (en) * 1966-03-31 1969-06-17 Theron V Moss Dry mop
CA2094875A1 (en) * 1992-05-01 1993-11-02 James A. Corbin Tufted fabric

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1825827A (en) * 1924-10-16 1931-10-06 Lea Fabrics Inc Single texture fabric and process of making the same
US2303203A (en) * 1940-03-18 1942-11-24 Nat Automotive Fibres Inc Carpet
US2349236A (en) * 1941-09-15 1944-05-23 Mishawaka Rubber & Woolen Mfg Carpet
US2675337A (en) * 1948-11-16 1954-04-13 British Celanese Method of producing an improved pile fabric
US2913803A (en) * 1957-10-22 1959-11-24 Artloom Carpet Company Inc Pile faced fabric

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR748136A (fr) * 1932-12-28 1933-06-29 Procédé pour agglomérer les fibres des garnitures de fibres et augmenter leur élaticité, et produits obtenus par ce procédé
DE846239C (de) * 1943-03-19 1952-08-11 Linoleum Werke A G Zweignieder Verfahren zum beiderseitigen Kaschieren von poroesen Stoffen, insbesondere Geweben mit plastischen Massen
US2794759A (en) * 1954-06-23 1957-06-04 Fiber Glass Ind Inc Method of making a resin impregnated fiber glass mat and product

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1825827A (en) * 1924-10-16 1931-10-06 Lea Fabrics Inc Single texture fabric and process of making the same
US2303203A (en) * 1940-03-18 1942-11-24 Nat Automotive Fibres Inc Carpet
US2349236A (en) * 1941-09-15 1944-05-23 Mishawaka Rubber & Woolen Mfg Carpet
US2675337A (en) * 1948-11-16 1954-04-13 British Celanese Method of producing an improved pile fabric
US2913803A (en) * 1957-10-22 1959-11-24 Artloom Carpet Company Inc Pile faced fabric

Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3206343A (en) * 1958-12-23 1965-09-14 Celanese Corp Method of pile construction
US3166465A (en) * 1960-05-27 1965-01-19 Int Latex Corp Bakced pile fabric and method of producing the same
US3347731A (en) * 1963-01-10 1967-10-17 Tapijtfabriek Noordester N V Device for manufacturing pile products
US3360421A (en) * 1963-05-10 1967-12-26 Du Pont Bonded nonwoven backing material having perforate selvage and carpet made therefrom
US3535178A (en) * 1963-10-31 1970-10-20 Bigelow Sanford Inc Method of producing tufted pile fabric and nonwoven backing fabric for the same
US3394043A (en) * 1963-10-31 1968-07-23 Bigelow Sanford Inc Tufted carpet and non-woven backing fabric therefor
US3546059A (en) * 1964-05-04 1970-12-08 Grace W R & Co Composite fibrous article bonded with novel copolymer compositions and method of making same
US3414458A (en) * 1965-12-16 1968-12-03 Du Pont Non-cracking tufted carpet with nonwoven secondary backing and method of making same
US3332828A (en) * 1965-12-28 1967-07-25 Monsanto Co Monofilament ribbon pile product
US3719546A (en) * 1968-03-14 1973-03-06 Bigelow Sanford Inc Lubricated non-woven fabric
US3535192A (en) * 1968-04-15 1970-10-20 Hale Mfg Co Carpet and method of making same
US3871948A (en) * 1971-04-01 1975-03-18 Bigelow Sanford Inc Non-woven carpet material with resilient backing
US4104213A (en) * 1976-11-26 1978-08-01 Cpc International Inc. Starch replacement for latex polymer
US5630896A (en) * 1992-05-01 1997-05-20 Hoechst Celanese Corporation Method of making recyclable tufted carpets
US5458944A (en) * 1994-04-15 1995-10-17 Fiberweb North America, Inc. Stretchable tufted carpet and stretchable nonwoven carpet backing therefor
US20110083792A1 (en) * 2008-06-05 2011-04-14 Entwicklungsgesellschaft Fuer Akustik (Efa) Mit Beschraenkter Haftung Velour carpet with tufting-like surface

Also Published As

Publication number Publication date
LU38499A1 (de)
FR1253594A (fr) 1961-02-10
CH372268A (fr) 1963-11-30
GB894234A (en) 1962-04-18
DE1238430B (de) 1967-04-13
CH425360A4 (de) 1963-06-29

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